Oxidizing petroleum and the products thereof



March 26, 1935. w. B. D. PENNIMAN I 1,995,324

OXIDIZING PETROLEUM AND THE PRODUCTS THEREOF i v Filed Aug. 13, 1925 Fig.1,

jwvewtoz Patented r. 2c, 1935 PATENT OFFICE;

OXIDIZING PETROLEUM AND THE PROD? UCTS' THEREOF William B. D. vlenniman, Baltimore, Md. Application August 13, 1925, Serial No. 50,108

g 22 Claims.

Thisinvention relates to a method of oxidizing organic substances, especially mixed or composite materials such as oils, pitches and tars rich in combined carbon, in a heated state and under pressure, employing an oxidizing agent in gaseous form preferably air, with the substance to be exidized, preferably present substantially in .excess; whereby oxidation of a selective character instead of ordinary complete combustion is effected in large measure and products of great industrial significance result. The invention furthe water-insoluble portion includes a light' I fraction available as an extraction solvent but of especial and notable value as a motor fuel for. internal combustion engines, a fraction utilizable as a varnish thinner or vehicle, and heavier water-insoluble products or oils utilizable in various ways, e. g. as burning oils, fuels, flotation 3o oils and the like. This application is a continuation in part of application, Serial No. 526,707,

filed January 3, 1922, Serial No. 541,525, filed March 6, 1922; and Serial -No. 541,526, filed March 6, 1922, the aforesaid applications con- ::5 taining subject matter from a prior application,

Serial No. 299,213, filed May 23, 1919.

' In accordance with the present invention, oxidized products are prepared bycontacting an oxidizing gaseous medium with the substance to be oxidized under relatively high pressure. Preferably the oxidizing gaseous medium such as air is passed through the substance in a liquid condition exposed to heat and pressure. Under such conditions as will be more specifically hereinafter set forth oxidation takes place in a predetermined manner and the products of oxidatfon or some part thereof are volatilized and carried away in the current of spent gas; the nitrogen of the deoxygenated air serving as a stripping agent, assistingiin removing the products from the zone of the reaction.

In the practice of my invention the substances which I prefer to 'treatare those which will exist in'a liquid or sufficiently fluent state to allow air or other oxidizing gas to bubble therethrough, under the desired temperature and pressure. Preferably I employ a deep layer or pool of the raw material in a liquid or molten state, into which layer or pool, air is injected preferably near the-bottom and bubbling upv 5 wardly through the hot liquid supplies oxygen to the latter while at the same-time bringing about a certain amount of agitation, thus creating a circulation which enables all portions of the liquid to be brought advantageously into 10 contact with the air jets or bubbles of air therefrom. It is, of course, possible to bring about agitation by special mechanical devices and such procedure is not precluded but is not recom mended for the high pressure operation forming 15 the preferred procedure hereunder. Baflles may be interposed in the liquid layer to' delay .the upward travel of the air bubbles, furnishing obstructions toits course in addition to the obstructing effect of the liquid or any solid mat- 2o ter such as carbon which may be suspended therein. The layer or column of oil preferably should be deep enough to rather completely deoxygenate the air during the period of its travel therethrough. Alayer at least 2 or 3 feet in 5 depth, therefore, is preferably employed but the precise rate of deoxygenation will vary with the pressure 'and other conditions. By complete or substantially complete deoxygenation in this manner the inflammablevapors' arising from the oil layer or column are not in contact with oxygen in any material amount thereby elimi nating a hazardof operation.

As noted, the substances which I particularly propose I to treat are those rich in combined 5 carbon and in general hydrocarbon mixtures of low grade such as crude petroleum and its vari-'- ous distillates,'shale products and tars, pitches, waxes, sludges and-residues of the petroleum industry; asphaltic oils, malthas, asphalt, cracked 40 oils and residues from cracking stills, wood tar oils and wood tars, peat distillates, lignite distillates and in some cases oils and tars resulting. from the destructive distillation of coal; also oils,

e. g., petroleum oil containing solid substances in suspension such as powdered coal, coke, peat and other oxidizable materials. Thus, finely divided bituminous coal may be suspended in petroleum and subjected to the oxidationstep as hereinafter described. Other ,substances, either solid or liquefiable by'heating, may be added to the oil forming the base raw material of oxidation. Ordinarily, it is not advisable to admix substances which are readily oxidized with those which are oxidized with great difficulty as the efficient manner, there maybe established the should be varied to secure advantageous conversion, specific in each case. However, the transformation of one rawmaterial undergoing oxidation with relative case may facilitate the oxidation of a substance of more difficult oxidizability and therefore I do not preclude the employment of mixtures of substantially dissimilar oxidizing rates, especially when one substance has a stimulating effect on the oxidation of the other.

A protracted series, of experiments and tests have shown that my process is especially applicable to the treatment of cheap petroleum oils in a liquid state, by bubbling the air orother gaseous oxidizing agent, under heatand pressure, therethrough. In this simple and, as I have found,

preferred oxidizing condition in accordance with which the oil to be oxidized is present in "predominant proportions; preferably being fed continuously into the charge in the oxidizing zone; thus reducing to a minimum the occurrence of ordinary destructive combustion, allowing the formation of valuable products of oxidation and substantially eliminating the hazard of explosive conditions which might prevail should oxygen be present in predominating proportions. In view of the richnessof petroleum in combined carbon and the adaptability of the process to the treatment of petroleum (mineral oils) and petroleum products in general as noted in the foregoing, I

a consider the controlled oxidation of petroleum to phur the oxygen may serve in part at leastasa desulphurizing agent, by oxidizing the sulphur to yield sulphur dioxide. Thus, distillates of rel atively low combined sulphur'content may be obtained. This reaction tends to simplify refining operations involving the elimination of sulphur.

The sulphur dioxide may be collected and converted into bisulphite solution or into any other suitable form. As the bisulphite itrnay be used to extract ketones or aldehydes in the subsequent operation of treatingand separating the useful products of oxidation. To the extent that sulphur is oxidized in this manner heat is developed in the oxidation zone and assists to the same degree of its development in the maintenance of the temperature of the reaction chamber. Hence oxidation reactions of this character are advantageous notonly from the standpoint of effecting desulphurization but also that of obtaining heat useful in the operation through the destruction of a deleterious substance. Any heat developed in this manner will lessen the heat required to be developed through the oxidation of desirable hydrocarbons. In some'cases sulphur may be added either for its calorific or chemical effect.

In the practice of one phase of my invention I have particularly in mind the possibility of oxidizing finely divided carbon'formed asa part of the general oxidation process applied to petroleum and the like. In this way I may supply to the reaction chamber a certain amount of heat while eliminating some of the carbon which otherwise would remain in the spent sludge or tar drawn from the oxidation chamber. In passing, it may be noted that the cracking of heavy petroleum conditions of temperature and pressure usually oils in direct fired stills gives much trouble through the separation of carbon which sticks to the bottom of the still and forms a graphitic layer causing overheating and burning out of the still hottoms. When employing high pressures in cracking, the problem is a serious one to find a sufliciently resistant steel in the construction'of the still bottom. In the present invention such carbon as is formed will at the time of its liberation bein a very finely divided state which, no doubt,

in part at least is colloidal and the oxygen-contairiing gas passing up .through theoil column comes in contact with these particles and is adsorbed. As a result the carbon may thus be oxidized selectively in greater or lesser degree, yielding a quota of heat for the maintenance of the temperature of the reaction zone. To the extent that heat is thus supplied by the oxidation of carbon useful work is performed. If the object is to secure from petroleum a substantial proportion of lighter hydrocarbons and a minor degree of oxidation, the heatsupplied by the combustion of carbon calls for less oxidation of the hydrocarbons themselves. dation of the very fine colloidal carbon I have therefore the opportunity of filtering the tar or spent oil withdrawn from the oxidation zone, thus removing'the coarser carbon which may be present and returning the filtered oil to the oxidation chamber.

With this tendency to' oxi- There exists within the range of utility of my agent employed preferably is ordinary air, utilized without drying or modifying the normal moisture content as it may vary from time to time. Or it may be dried, if desired, to a uniform degree of humidity. Likewise for special purposes, moisture, for example, as steam maybe introduced'with the air blast. When the pressure required to prevent premature volatilization of the oil is so great that the consequent pressure of the incoming air yields too drastic a degree of oxidation, the air may be diluted with steam or diluent gases such as products of combustion, or with deoxygenated air discharged from the condensing apparatus. The enrichment or improverishment of this entering air is also determined by the character of the oil or the products needed. On the other hand, when treating highly resistant organic material such as the spent oils from cracking stills or for securing deep-seated oxidizing effects the air may be enriched with-oxygen. Pure oxygen obtained for example by the liquefaction of air could be used in this manner. Air at ordinary atmospheric temperatures may be used but in most cases I prefer to preheat the air to a considerable degree. Since my process of oxidation is preferably carried out at relatively high pressures, usually exceeding ten atmospheres and frequently consid- 'erably higher, the air is normally sufficiently temperature may be further increased in some cases by having the compressed air travel through a heat interchanger before entrance into the reaction chamber. The heat interchanger may be arranged to utilize some of the heat of the outgoing gases and vapors. In some cases a coil may be placed in the upper part of the reaction chamber through which the air travels before entering the oil. The air thus compressed and preheated preferably isintroduced into the oxidizing chamber in the lower part thereof where it is forced through the column of oil, preferably through distributing devices which cause the air to be projected into the oil as fine jets or bubbles. On entering the oil the air bubbles encounter the resistance of preferably a deep column of saidoil and this obstructing effect is oftentimes enhanced by the presence of carbon or other solid materials. The fine bubbles of air, therefore; may travel rather slowly upward through the pool of oil. As previously noted, the rate of travel may be retarded to an additional degree by the employment of baffles or other devices arranged to hinder such upward flow. If the baffles are arranged in a manner to bring about a circulation of the oil which tends to cause the carbon and other separated solid material to collectto a considerable degree in the lower part of the reaction chamber this is advantageous as the tarry material or heavy liquid products remaining from the reaction may be drawn off at the lower part of the chamber, either continuously or intermittently,

- as desired.

chemical changes to be oriented to a considerable degree despite thelcomplexity of such bodies as petroleum and other oils. In the cleavage of hydrocarbons of high molecular weight when exposed to heat, while accompanied by exposure to oxidizing agents products of lower molecular Weight some of which are more stable than others will form. There is, therefore, a tendency for the more stable bodies to accumulate. ,If sufiiciently volatile these will be carried away in the stream of deoxygenated air to the condensers or absorbers. If non-volatile under the conditions of treatment, they may remain unchanged in the oil and be drawn off with the sludge, from which such products maybe recovered by suitable treatment. Or yielding to further and'continued oxidation they may break down further. Under one setof conditions a maximum yield of water insoluble products containing a substantial proportion of com ponents available for motor fuel purposes will result whereas under a different set of conditions there may be an increased yield of more highly oxidized products, for example those of a water-soluble character such as the lo'wenfatty acids, lower aldehydes, solvents, and the like.

Chemical oxidizing agents such as metallic sure or more strictly a c itical range of pressure yielding a maximum proportion of specially desired products of oxidation. Beneath this range inadequate yields or indifferent results appear while above the range there is danger of destructive eifect, through condensation, polymerization and so forth. 7 I

If the raw material is very cheap such a degree of destruction is notalways as serious, since other effects such as the spontaneous development of heat useful in the reaction or the. elimination of some impurity, e. g. sulphur or carbon may determine the conditions imposed, and pressures within the critical range at the approved temperature may therefore not always be required. However, I prefer to approximate this range. Likewise there exists a critical temperature or range of temperatures at or within which the maximum yield of particular products may be expected. In some cases thisrange is a broad one for example between 300 and 1000 F. A narrower and more effective range is that between 600 and 900 F. For the treatment of petroleum oils to obtain oxidized products and especially motor fuelssubstantially free from knocking qualities when used in internal combustion engines I preferably employ a temperature between 700 and Restated, the process in its preferred form is that of passing air at the critical oxidizing pres- 7 sure and temperature or within a range which embraces such critical pressures and temperatures, through the substance to be oxidized, which is present in a liquidform or as a suspension in an appropriate liquid or molten material, and separating from the spent air current the desired products of oxidation and entrainment.

From the residues of oxidation products. which are non-volatile under the pressure conditions- ,imposed or are not entrained by the spent air respect to the orientation of oxidation. At low pressures air acts as an entraining rather than a sheer oxidizing agent while at high pressures its oxidizing activity is surprisingly enhanced and,

the entrainment of heavy unoxidized bodies becomes a minor occurrence. This is a desirable condition to create since it permits oxidation.

ta continue on the substances not oxidized or sufficiently oxidized while products of lower molecular weight and of greater volatility or more easily sublimed will be removed from the zone of oxidation and further conversionarrested. As the pressure is increased the entrainment tends to diminish and may become a negligible factor with respect to' the unoxidized bodies present in the reaction zone.

The spent air current or deoxygenated air therefore acts as a sweeping-out or purging agent to remove lighter bodies from the zone of oxidation and to prevent destructive oxidation to such ultimate products as carbon monoxide or carbon dioxide.

The employment of high" pressures has the additional advantage that a comparatively small volume of gas is required to effect oxidation. This allows for more compact apparatus, piping and the like. Furthermore, the degree of entrainment is much less when the volume of gas is reduced. Entrainment which removes the products of oxidation from the reaction zone is desirable but too great a degree thereof carries away from the reaction chamber a large proportion of the raw material which subsequently has to be separated from the products of oxidation and oftentimes this is not an ec'onomical procedure. Bythe employment of the highly compressed gas diminished by pressure to say one-twentieth or one-fiftieth the volume that it would occupy at ordinary atmospheric pressure, the degree of ebullition, spraying. and foaming is greatly reduced.

A bubble of air exposed to a pressure of 300 pounds above atmospheric has twenty times more oxygen at its reacting surface than at ordinary atmospheric pressure. At 900 pounds pressure the oxygen at the surface is sixty times greater and at 3000 pounds, pressure there is present two hundred times more oxygen.

Thus, as the bubble passes through the hot material which is being oxidized the number of oxygen molecules ranged along the surface of the bubble for attack on the raw material is greatly altered by pressure and new and surprising ef-- fects are obtained by such alteration.

With some substances extremely high pressures may cause too extensive oxidation. On the other hand, pressures. only slightly above atmospheric would bring about little or no action and the oxidation would proceed at so slow a rate that the process would have little commercial interest.

Aside from the effect of any finely divided carbon present in the oil there may be added special activating substances such as aluminum chloride, the oxides of manganese, lead, iron, chromium, vanadium, zinc, copper, or calcium and the like to assist in the oxidation; such substancesordinarily being introduced in small or catalytic proportions. Larger amounts of alkaline substances or bodies having a utralizing effect such as quick lime, lime sto e, or carbonated alkali may be added ,in some cases. In general, however, for carrying out the reactionon petroleum oils I do not require any catalytic or activating substance. treating native petroleum or its fractions which have been unchanged by cracking or otherwise. Catalysts, however, sometimes may beused ore advantageously on rather resistant coal tar dis,- 1

tillates, spent oils-from cracking stills, and similar raw materials which have experienced a treatment which tends to render them normally more stable and therefore less easily attacked by oxygen. J

{lhe oxidizing chamber may be of heavy steel plate which, if desired, may. be of chromium steel or chromium nickel steel orother material fairly resistant-to the attack of sulphur, sulphur dioxide and organic acids. The chamber preferably is cylindrical with concave or convex heads to withstand the high pressures employed in accordance withthe preferred embodiment. In appearance it may resemble an ordinary direct fired oil still. The cylinder may be placed horizontally or vertically. In the latter'position a tribution of compressed air.

This is especially .true when single distributor placed at or near the bottom ordinarily will serve for the admission and dis- In the horizontal form the air may be introduced through a perforated pipe situated along the bottom and extending from end to end of the oxidation chamber. The movement of air upwardly through the oil causes the latter to swirl and circulate in a brisk manner, upwardly, then outwardly towards the walls of the vessel and finally downwardly toward the source of air supply. Such circulation is effective in bringing about good contact between the oil under pressure and the compressed air supplied to it. The air jets may also be so arranged that the movement of oil within the still is such that the heavier products are segregated in a selected portion of the still itself or an attachment thereto. The motive power of the air may also be utilized before or after discharge to move paddles or other mechanical devices as may be desirable for the same purposes. There need be no fire -box or other provision for continuously heating the oxidizing chamber. The latter is preferably a fireless still the temperature of which is maintained solely by the heat of oxidation generated within the thick layer or column of oil, or preferably jointly by the heat of oxidation and the heat supplied by the compression of the air supply; or by specially fired preheaters for the oil and/or air.

However, the foregoing does not preclude the employment of oxidizing chambers equipped with fire boxes if these are desired. The latter, for example, may be used only during the initial or "starting-up period. When the oil has been heated sufficiently so that the oxygen of air will react with it, the blast of preheated air may be.

. subside entirely.

Using a fireless still without firebox equipment the oil may be heated in a convenient receptacle to a temperature of say 500 or 600 F. and then charged into the oxidizing chamber. Air, preferably preheated is introduced and with an effective pressure in the chamber the oil begins to oxidize and thetemperature will rise to say 700 or 750 F. remaining at that point by adjustment of air supply, the degree of preheat thereof and the continuous introduction of preheated raw oil. In short, once an initial charge of oil has been heated to oxidizing temperature in a chamber continuously supplied with oil no 'f-urther application of heat by means of fireof travel from the point of its ingress to the surface of the oil. It is desirable also to withdraw a portion of the oil continuously from the reaction pool, preferably from the lower part. The rate of withdrawal may be adjusted with respect to the rate of feed of the oil into the chamber to avoid departing materially from a constant level. Instead of continuous feed and discharge the operation may be intermittent portionwise, e. g. frequent alteration of feeding in portions and withdrawing portions without substantially disturbing the constant level conditions of the reaction pool. 7

The introduction of fresh raw oil into the still serves to maintain a degree of constany of oxidizing conditions which is desir'able. The contents of the chamber remain more uniform an when a charge of oil is placed in a recep acle and blown with air until action substantially ceases. With continuous feed of oil or its equivalent the air is at all times acting on a mixture of fresh oil and of oil which .has been modified through reaction. Continuous introduction and withdrawal thus suifice to obtain -that.relatively constant composition which is important in securing uniformity of heat development and effective supervision of the apparatus.

The intermittent or-batch process yields constantly changing conditions as oxidation progresses and finally comes substantially to a standstill. In this case the conditions of operation are constantly'changingand there is less effective control with variable conditions of heat development. Therefore, while certain features of the present invention may be practiced by the in- .termittent process, it does not constitute the preferred embodiment.

The continuousfeed of oil also brings about a safer character of operation in that there is alv ganic acids, which may include ways present an abundance of fresh raw oil to which the oxygen has access and therefore the risk of collection of an excess of oxygen'at any one point to bring about violent local reactions is minimized. The employment of an average pool of oil therefore constitutes whatI consider to be a very desirable feature of the prefer-red form of my invention.

4 Condensation of the vapors is preferably car ried out under a pressure above atmospheric, nor mally approximating the same pressure as that of the oxidizing chamber. Condensers may there-.

fore be in open communication with the oxidizing chamber and such pressure drop as may be observed in the different parts of the condensing apparatus will be simply, that due to condensation and loss of pressure by friction. However, there may be provided a shut-off valve or a check valve between the still and condensers of the several sections of the latter to cut off any desired units or to reduce the pressure thereinv Condensation at atmospheric pressure is not precluded and the employment of silica gel, adsorbent carbon or similar adsorptive agent is considered advantageous in the treatment of the tail gases to remove residual vapors such as light aldehydes and very volatile hydrocarbons. The tail gases thus treated will be found to contain a very high proportion of nitrogen which may be purified and used in admixture with hydrogen to make synthetic ammonia.

The condensate is acid due to a variety of orformic, acetic, propionic, butyric and higher fatty acids of this ,series, also unsaturated acids, e. g. acrylic, aromatic acids, e. g. phthalic acid or anhydride. Sulphur dioxide also may be present. Hence I prefer to construct condensers or at least that portion in which the acids. condense, of material, e. g. copper, chrome steel, nickel chrome steel, Monel metal and the like, notably resistant to upper layer of oily character and a lower layer of a water solution of organic substances. The emulsion or two layer condensate may be' highly charged with gas particularly when pressure condensa tion has been used. The upper layer which contains water immiscible substances is hereinafter referred to as motor distillate.-

Each of these distillates may be worked up in a number of ways to produce valuable commercial products. a

As previously indicatedthe character of the distillate is determined by a numberof facto'rsythe most important of which are indicated below:

First, character .of hydrocarbon used;

Second, pressure maintainedinf the still;

Third, rate and rapidity of the entering air and any additions thereto;

Fourth, the temperature maintained in the still;

Fifth, the temperature maintained in the reflux head; Y

Sixth, mode of condensation The products of oxidation, distillation, and

condensation thus attained are hereinafter referred to as oxygenated and disintegrated products; Apparatus which may be desirably used is shown in the accompanying drawing, wherein: Figure 1 is a diagrammatic section or elevation of a battery of stills including the reaction chambers, dephlegmators and heat interchangers in which the process maybe carried out; and Figure 2 is a modified form of air nozzle. Referring to Figure 1 more specifically, there is shown a battery of stills in which a multi-stage oxidation of the petroleum oil may be carried out. This apparatus includes a series of tanks or stills each of which is desirably made of heavy walls adequate to sustain pressures of 300 pounds or more per square inch. The still may be made in two sections, secured together by companion flanges and suitable bolts. The initial still 25 may be heated at; the start of the process by a furnace 26, the still and furnace being preferably surrounded and reinforced by a concrete and insulating material 2'7. Stills 28, 29, 30 may be provided with similar heating apparatus but this is not essential in view of the fact that the oil received by these latter stills is in a heated condition, being generally derived from the first still 25. The .oil after treatment in each still is passed to the next subsequent still by means of pipes 31, I

32, 33, each of these pipes'leading respectively from the upper liquid level of a preceding still point. Air is supplied to the stills preferably at the bottom thereof from'an air compressor 35 by means of which the air at the requisite pressure to overcome the pressure within the stills is supplied to a pipe 36 from which it is led by suitable branch pipes, or otherwise supplied with the nec-' essary'valves for controlling the supply, to a distributor 3'7 in the bottom of the still 25, and similar and entering the next succeeding still at a lower distributors 38, 39, 40 in the bottoms of each of 'phlegmators, the type of material which is car-- cut upon heating the air. Each of the stills 25, 28, 29, 30, is provided with a run-back or dephlegmator. Heat interchangers 60, 61, 62, 63, may be used. By the use of such run-backs or deried out of the still is readily controlled. As it is sometimes found desirable in the way of increasing the efficiency of the oxidation process by increasing the percentage of volatile constituents in theproduct, each still head maybe provided with a coil 46 connected to live and super heated steam mains 47, 48 respectively, controlled by valves 49 and 50, so that the vaporized or oxidized products and gases from the still may be treated at this point at any desired temperature, either heated or cooled, to assist in the separation of desired materials. The flow of steam to any or all of the coils 46 may be cut off completely by means of valves 51.- In the dephlegmators a portion of the heavier hydrocarbons is subtracted from the mixture of gases and hydrocarbons given olf by the still, the separation being by condensation and backflow of the heavier materials From the still heads the hydrocarbons and oxidized materials are carried by and with the gases and vapors, such as nitrogen, steam, and carbon dioxide, through the manifold '70 to the condenser coil '71 which is immersed in cooling liquid in the tank 72. Beneath the cooling tank '72 is a receiving tank 73 for the condensate, the lower end of the coil 61 being arranged to deliver into this tank. The tank is closed and provided with a sufficient gas space above the liquid, which space is'vented by a pressure regulating valve 54, the latter being adjustable as to the pressure of release.

Other features of the apparatus, provided forconvenience in handling the material, are blowout pipes 55 leading from the bottom of each tank, the same being controlled by valves 56; and by-pass connections 57, each connected by a three-way valve 58 with the transfer pipes 31, 32, 33, the same being available to remove the oil undergoing treatment to a common receptacle wherever it is desired, 'or to transfer the oil from one tank to the other opposite to the direction of circulation, the universal path for removal of the oil after treatment being by way of the pipe 55 from the end still 30 of the battery.

In operation, the liquid hydrocarbon to, be treated is supplied to the still 25 by means of pipe 30 where its temperature is raised by means of external heat, either from the furnace 26 or by means of heated air from the coil 42. When a temperature sufiicient to cause the direct cdmbination of the air with the oil has been reached,

no further external heat is necessary, and the burner 43 or the furnace 26, whichever is being used, may preferably be extinguished. After treatment in the first still, the residual oil is passed to the second still where it is again subjected to oxidation under superatmospheric pres- .soluble organic material.

desirable to maintain the pressures approximately the same and over 300 pounds per square inch, desi gably around 400 pounds. By the use of pumps on the oil lines between the'several stills constituting the battery, the oil is readily transferred from one still to the next. The gases and vapors from the several treatment stills may be combined for-treatment or may be separately collected and treated. Where the conditions of treatment and the materials being treatedare substantially the same in each still, the gaseous and vaporous products may be conducted to a single condensing train. However, since the overflow from the first still to the second still, and so on, is usually heavier, it may prove desirable to treat the gaseous and vaporous products from each oxidation zone separately. The condensation is desirably carried out under pressure.

In treating the gaseous'and vaporous products from the oxidation zone fractional condensation is desirable. For this purpose products coming off from the stills may be condensed in a condenser using water maintained near its boiling point, for example, around 175 F. A portion of the vaporous and gaseous material is here con- .densed and collected. The remaining gases and vapors are passed then to a second condenser, preferably kept cold, refrigeration being used if desired. Scrubbers or absorbers may also be used to remove the desired products from the gases.

When using the fractional condensation method set forth above, the condensate from the hot water condenser will contain most of the water from the vapors and gases and a considerable amount of water soluble organic material. There will also be some water insoluble material condensed at this point. If sufficient water insoluble material is condensed at this point the condensate may stratify into two layers, a lower one containing the water solution of organic substances and the upper layer containing water insoluble organic material. The condensate from the cold condenser will also contain some water and water soluble organic products and water in- This condensate will also generally stratify upon standing, particularly if removed from the pressure zone, into two layers, the upper one containing the water insoluble organic material and the lower awater solution of organic substances, Each of the condensates referred to above may be separated into fractions containing the separate strata referred.

sure. Similarly the oil residues are successively'Wures 14' are preferably formed by tapering nozdrawn from the second and third stills for treatment in the next succeeding stills. The number of stills used may vary, depending on the character of material undergoing treatment and the conditions of treatment to which it is subjected. In using such multi-stage oxidation treatment the conditions prevailing in each chamber need not be identicalp For example, the temperatures in the succeeding chambers may become progressively higher by increments of, say, 50 F. Further, the pressuresin succeeding stills need not be the same, although it is generally found to be zles 15 having their small cross-sectional area at the outer or delivery end 16' .ofsuch nozzles. With this construction there is no tendency toward accumulation of carbon in these nozzles and no localized heat accumulation due to secondary combustionof such accumulated carbon.

The following specific example is given to illustrate the invention as applied to a typical petroleum oil,,but it will be understood that this specific form is merely illustrative and not limiting, since many changes, may be made therein by those skilled in the art without departing from the spirit and scope of this invention. This example will illustrate the process preferably used and the products derived therefrom, but due to the conditions of treatment which may be varied as set forth above, and due to the widely variant character of material that'may be treated in this process, theproducts produced may vary within wide limi s The hydrocarbon used was a Mid-Continental gas oil containing about one percent of sulphur,-

and having the following characteristics:

Each still used was a vertical one, four feet in diameter and twenty-six feet high. The airjets were three feet from the bottom of the still.

A cooling coil on the head of the still was arranged so that the vapors and gases-passing to the condenser were maintained at a temperature of 315 F. The oil was preheated to 500 F. before the still was operated. The still contents of 23 barrels was maintained during the run. The pressure in the still was 300 pounds during the run, and the air used was about 300 cubic feet per minute, the pumppressure being about 350 pounds. After the air was turned into the still, the temperature rose from 500 F. to 725" F. to 750 F. Distillation was evident soon after the air was turned into the still. The rate of distillation increased as the still and its contents heated up, but after the desired range of temperature was reached, it was kept approximately constant during the run by evident slight manipulation of the entering air, oil and sludge withdrawal. The charging oil was in part new oil and in part oil that had been separated from the sludge of the previous run. The average input and output of the still per hour were as follows:

Carbon dioxide and water equivalent to 7 gal a lens of oil.

Volatile hydrocarbons escaping an olrdinary con The distillate obtained during this test as it runs from the condenser is an emulsion highly charged with gas, and is referred to as intermediate distillate. It, was run into a wooden tank and allowed to-stand until a fairly sharp separa- Oll 100%.

4 bbls. per hour.

Net oil used 4-1.4-

2.6 bbls.

.tion into two layers took place. Separation in the.

receiver under pressure is usually much slower.

This separation results in an upper layer contain ing water immiscible substances, and a lower layer containing a water solution of organic substances. But since some of the constituents are mutually soluble, there is a distribution of these mutually soluble substances between the two layers. Some of the valuable organic substances found in the 'caustic solution in a variety of ways.

water used being carefully proportioned so as to avoid an undue dilution of the organic material that ought to be recovered. Washing several 4 1 times using from 3 to 10% of water for each wash effects a satisfactory'separation. These water washes from the upper layer are added to the lower layer. v

In the typical case given above as an illustra-- tion the intermediate distillate was separated into two portions: the upper layer containing the 10 water insoluble crude oxidized distillate and the lower layer containing therwater soluble crude oxidized distillate. The following methods used for treating these distillates to recover valuable products therefrom are exemplary only and not 15 limiting in any way.

A portion of the water insoluble crudeoxidized distillate was treated with ten percent caustic soda solution inan agitator for about one hour.

Acids, phenols, aldehydes, etc. which are present 20 are dissolved, and can be separated from the Another portion was first treated with a ten percent solution of carbonate of soda to remove the acids,

and then with caustic soda. to withdraw the aldehydes (as gum) and the phenoloid bodies- In a third portion, the aldehydes were first largely withdrawn by means of a concentrated solution of sodium bisulphite, the other desirable sub-- stances being subsequently removed by'the use of 30 methods analogous to those set forth above.

Following the treatment with caustic soda the material may be, washed with water and then treated with a small portion of sulphuric acid.

If strong acid is used it is advantageous to keep 35 may be used, the distillate up to 400 F. being 40 separately collected. A further fraction taken between 400 F. and 500 F. may also beutilized. The conditions of treatment are varied so that a motor fuel with the customary end point of 437 high yields in this process, for example, 40% of such motor fuel and, if desired, the process may be forced to give higher yields, say up to to For general commercial operation using P. is obtained. It is a simple matter to obtain 45 pressures around 400 pounds in the oxidation 50 zone,.40% yields of motor fuel are commercially practicable.

In the fraction up to 400 F. is a gasoline substitute which differs markedly in its properties from the ordinary commercial varieties of gaso- 55 gasoline substitute referred to above contains 60 oxygen which may amount to 3% or more. It has a characteristic odor. Further, this motor fluid will stand a high compression in the motor cylinder without premature ignition. It is also proportions and can be mixed with ordinary gasoline, benzol, acetone and organic liquids in gen,- eral. Blended fuels may thus be made. In some cases to meet the requirements of some of the States, where motor fuel gasoline or its equiva- 70 lent must be of a color corresponding to 16 Saybolt or better, it may be necessary to refine the motor fuelreferred to above with such bleaching agents as will yield this color.

The residue remaining in the still after re- 75 readily soluble in ordinary' alcohol in all 65 moval of the volatiles therefrom in this treatment of the motor distillate, is desirably returned to the oxidization still for retreatment.

Sulphuric'acid material derived as set forth above is substantially different in its properties from the acid sludges obtained from treating ordinary petroleum and its distillates. This is due to the presence of alcohols in the crude water insoluble-oxidized distillate, which alcohols combined with sulphuric acid in a manner different from that of the unsaturated substances predominating in straight petroleum distillates. This novel sulphuric acid sludge is diluted with water and steam stilled. The alcohols which are distilled off and the organic residue that remains in the still may both be utilized.

Other methods for treating the crude water insoluble oxidized distillate may be used. For example, this so-called motor distillate may be purified by passing it through fullers earth, silica gel, or heated bauxite. Or in another method of treatment the distillate may be redistilled with aluminum chloride. Or again, in order to separate aldehydes particularly, the distillate after treatment with sodium carbonate and sometimes after the caustic soda treatment, may be distilled with aniline in amount equal to 5%, for example, or with phenol, either being used in any required proportion. V

The water soluble crude oxidized distillate was separated as set forth above from the water immiscible content of the intermediate distillate. This water solution of organic substances was found to,contain approximately 18% of organic material "of the following composition: 3% of acids, mostly acetic, with indications of dibasic acids; 7% of aldehydes, principally acetaldehyde and proprionaldehyde; 3% of ketones including acetone; and 5% of alcohols, both saturated and unsaturated. This water solution is treated as follows: 15 bbls. are placed in a copper still provided with a high fractionating column. 12 fractions of 7 gallons each are taken from this still ranging in boiling point from about 20 C. to 95 C. The firstand second fractions consisted of practically pure acetaldehyde, the last fraction containing, however, a considerable? quantity of water. contained only small amounts of water and the boiling points ranged up to C. These distillates are rather complex and have been found to contain aldehydes,'ketonessalcohols, and acids as well as unsaturated compounds and compounds formedlby combination of the substances gust mentioned. Acetaldehyde is very readily separated by distillation. Distillates '3 to 12 inclusive, were treated with caustic soda solution and redistilled. The caustic soda acted to fix the aldehydes and acids and perhaps other substances.

leaving a resultant white solvent of boiling point range from 45 C. to 85 C. This white solvent amounted to about two-thirds of the organic matter present in the original water solution of organic substances obtained from the intermediate distillate. It is a clear, transparent liquid with a pleasant odor. It mixes in allproportions with water, alcohol, ether, benzol,' and petroleum. It mixes with gasoline in allproportions and gives to the latter anti-knock properties, It also mixes with kerosene and reduces its knocking properties in the motor. This white The intermediate fractions'.

are improved for many purposes. The .white solvent or fractions thereof can also be used for theextraction of fats and medicinal principles. For desired purposes, awhite solvent substantially free from acetaldehydes can be obtained by subjecting the watery liquid remaining after distilling ofi mostof the acetaldehyde from the crude water soluble distillate, to further distillation after the addition of anilin to fix any remaining aldehydes in the form of gummy material. This method of fixing the aldehydes may also be used in the treatment of the crude water insoluble distillate referred to at length above. In either case, any excess anilin may be easily removed from the distillate.

The neutral or alkaline still residue remaining after the white solvent separation, was treated with sulphuric acid until acid whereupon substances combined or dissolved by the soda solution were set free. It was then steam distilled and the organic distillate reworked. The residual gummy liquid which is insoluble in water is first washed and thenmaybe combined with aniline or its isomers, hydrazine or its isomers, phenol or its isomers, or a combination of them, in either acid or alkaline condition. The gummy liquid if dried and subjected to heat treatment can be used for making gums of varying hardness as may be desired. The gum can also be used in admixture with other. gums and substances.

A portion of the caustic soda used in the treatment of the crude oxidized distillate insoluble in water was also worked up by acidifying it and steam distilling it. The distillate contained the volatile fatty acids and phenoloid bodies, which were readily separated by carbonate of sodium. The residual gummy substancewhich remained was utilized in the same manner as the gummy liquid obtained from the water solution referred to above.

The oil which is withdrawn from the main treatment still during the pressure oxidation and disintegration and any residue in this still, contains oxygenated derivatives and may be worked up to separate fatty acids, for example, but is preferably returned to the still for retreatment.

The various factors set forth above for controllingthe character of the distillate are easily adjusted so that the runback .of the still is reduced to'a minimum. The process may be made practically continuous. The carbon formed during the process -may be withdrawn from the bottom of the still from time to time, say at intervals of an hour, and oil supplied continuously. The position of the air nozzle controlling. the point of entry of the air into the liquid hydrocarbon undergoing treatment is one factor affecting recovery of carbon from the still; For example, the further the nozzle is placed from the bottom of the still, the less is the circulation caused in the oil by the incoming air. When placed about 'three feet above the bottom of the still, there is a zone of quiescence inwhich the carbbn formed during the process may accumu late. .However, when placed about 18 inches above the bottom of the still the oil is in circulation throughout substantially all portions theresolvent or fractions" thereof is a solvent for Shlfl from th tm, I

lac, gums, nitrocellulose and cellulose esters in general, andwhemthe-alcohols present are combined with organic acids the solvent properties In general, it should be noted that the process of pressure oxygenation and disintegration here,

in set forth is essentially different in character tion of oxygen during the treatment.

from the cracking processes, etc., heretofore known to the art. The products produced in the instant process strikingly emphasize this differentiation. Furthermore, in the present process it is possible to obtain yields of more than 100% based on the treated oil since there is a combina- While the process as set forth above is exemplifled by the treatment of hydrocarbon material, such material may be given a chemical treatment to produce chlorinated, nitrate'd, sulphated or other derivatives in the material before 'it is subjected to the times found to be desirable to use condensers supplied with brine instead of with water.

Further, the eifiuent gases and vapors may be subjected to the action of a distilling head which acts either as a preheater, or to return all or a portion of the material to the still for further treatment or to a supplementary still'or vessel for supplementary treatment.

The chemical and physical treatments set,

forth above may be carried out in towers under superatmospheric pressure if desired. In carry-' ing out the various fractionation treatments that are set forth above, or for carrying outother fractionations which may prove desirable, bubble towers maybe found desirable-and in such cases should, of course, be used.

Having thus set forth nty invention, I claim? 1. A process of oxidizing petroleum which comprises passing air through a body of hotpetroleum of depth sufficient to deoxygenate said air, withdrawing the residue of treated petroleum and blowing air through the hot residue, each oxidation treatment being carried out under super-atmospheric pressure.

2. An oxidation process for the treatment of petroleum which comprises treating hot petrolearn oil with'air under super-atmospheric pressure, the conditions of treatment being sufiicient to deoxygenate said air during its contact with the hot petroleum oil to produce vapors and gases, and recovering products from said vapors and ases. I

3. In the multi-stage oxidation process of treating heavy hydrocarbons wherein air is passed through a body of hot heavy hydrocarbons under su'penatmospheric pressure in a series of treatment zones, thestepfof maintaining the body of oil of a depth of atleast three feet.

4. A process of treating oil which comprises passing preheated air through a body of hot oil resisting the passage of air therethrough, in a series of treatment zones maintained under super- 'atmospheric pressure, the resistance of the oil to the passage of the air being enhanced by the presence of solid materials.

5. The process as set forth in claim 4 wherein the resistance of the oil to the passage of airis enhanced by baflies. V v

6. A process which comprises passing air through a body of hot oil resistingthe passage of air therethrough in a series of treatment zones maintained under pressure greater than atmospheric, the resistance of the ofl to the passage of air being enhanced by baflies arranged to cause circulation of the oil whereby the carbon and other separated solid material collects to a considerable degree in the lower part of each treatment zone.

7. A process which. comprises passing air through a body of hot petroleum in a series of treatment zones under pressure greater than atmospheric, the point of entry of the air into the oil being" varied to control the distribution in the treated oil of carbonformed during the reaction.

8. The process of desulphurizing oils which comprises passing a current of an oxygen-containing gas through a pool of a sulphur containing oil in a series of treatment zones maintained under super-atmospheric pressure and at a temperature suflicient to produce oxidation of the sulphur, whereby sulphur dioxide is formed and eliminated.

9. The process of disintegrating relatively heavy non-volatile oil which comprises bubbling air therethrough at temperatures of from 600 to 900 I. in a treatment zone maintained under super-atmospheric pressure, withdrawing the products of oxidation and disintegration and separating them into various portions.

10. The process which comprises passing air into hot sulphur containing petroleum in a treat ment zone maintained under super-atmospheric pressure whereby'desulphurization is obtained, and recovering distillates of relatively low sulphur content from the treated petroleum.

11. The process which comprises passing air through a layer of hot oil in a series of treatment'm zones maintained under super-atmospheric pres,- sure to produce light products of oxidation and disintegration of the oil,- and recovering such light products from each treatment zone.

12. 'A process of treating petroleum which comprises passing, air into hot petroleum in a treatment zone maintained under super-atmospheric pressure to produce gaseous and vaporous products of oxygenation and disintegration, and fractionally condensing such products.

13., A process which comprises passing 'air into hot petroleum in a series of treatment zones maintained under super-atmospheric pressure, whereby sulphur dioxide and volatile oxygenated and disintegrated products containing aldehydes and ketones are formed, separating the sulphur dioxide and converting it into bisulphite, and extracting the aldehydes and ketones with such bisulphite. v

14. In the process of treating hot liquid hydrocarbon by air-blowing under pressure in a series of treatment zones, the step of maintaining the pressure high enough to minimize the entrain- 1 ment oi unoxidized and undisintegrated hydrocarbon by escaping gases and vapors.

15. In the process of treating liquid hydrocarbon by air-blowing in a series of treatment zones maintained under super-atmospheric pressure, the step of maintaining the pressure high enough to minimize ebullition, spraying and foaming.

16. A Stratified two-layer condensate from the pressure oxidationand disintegration of petro water solution of 17. As a two-layer condensate from the oxida-' tion of petroleum by air-blowing in a series of treatment zones maintained under super-atmospheric pressure, an aqueous solution comprising aldehydes and organic solvents forming the lower layer" and a superposed layer comprising antiknock motor fuel.

18 .-As a two-layer condensate from the oxidation of hot petroleum by blowing air therethrough in a. series of treatment zones maintained under super-atmospheric pressure, an aqueous solution of organic bodies forming a lower layer and a superposed layer comprising water insoluble motor fuel. v

19. A motor distillate obtained from the oxidation of hot liquid petroleum in a treatment zone maintained under super-atmospheric pressure, such motor distillate containing a, higher percentage of oxygen containing materials than does ordinary cracked gasoline.

20. A multistage process of treating hydrocarbonoils which comprises maintaining a body of oil under pressure and at conversion temperature by supplying controlled quantities of oxygen con-' taining gas into the body of oil, treating fresh oil with an oxygen containing gas to raise its temperature, and adding said fresh oil to the body of oil undergoing treatment, and withdrawing vapors from the body of oil.

21. A multistage process of treating hydroc'arbon oils which comprises maintaining a body of oil under pressure and at conversion temperature by supplying controlled quantities of oxygen containing gas into the body ofoil, treating fresh oil with an oxygen containing gas to raise its temperature, adding said fresh oiltothe body of oil, and withdrawing vapors from the fresh oil during its treatment with the oxygen containing gas.

22. A multistage process of treating hydrocarbon oils which comprises maintaining a body of oil under pressure and at conversion temperature, treating fresh oil with an oxygen contain- 20 ing gas to raise its temperature, and adding said fresh oil to the body of oil. v

WILLIAM B. D. PENNIMIAN. 

